WO2005025861A1 - 光輝性を有する化粧紙及び熱硬化性樹脂化粧板 - Google Patents

光輝性を有する化粧紙及び熱硬化性樹脂化粧板 Download PDF

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Publication number
WO2005025861A1
WO2005025861A1 PCT/JP2004/013248 JP2004013248W WO2005025861A1 WO 2005025861 A1 WO2005025861 A1 WO 2005025861A1 JP 2004013248 W JP2004013248 W JP 2004013248W WO 2005025861 A1 WO2005025861 A1 WO 2005025861A1
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WO
WIPO (PCT)
Prior art keywords
resin
paper
decorative
glittering
ink layer
Prior art date
Application number
PCT/JP2004/013248
Other languages
English (en)
French (fr)
Inventor
Kazuhiro Hama
Takashi Iizuka
Original Assignee
Dai Nippon Printing Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dai Nippon Printing Co., Ltd. filed Critical Dai Nippon Printing Co., Ltd.
Priority to EP04787888.9A priority Critical patent/EP1666244B1/en
Priority to US10/570,739 priority patent/US20070036984A1/en
Publication of WO2005025861A1 publication Critical patent/WO2005025861A1/ja

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/10—Applying flat materials, e.g. leaflets, pieces of fabrics
    • B44C1/105—Applying flat materials, e.g. leaflets, pieces of fabrics comprising an adhesive layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • B32B3/16—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side secured to a flexible backing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/10—Applying flat materials, e.g. leaflets, pieces of fabrics
    • B44C1/14—Metallic leaves or foils, e.g. gold leaf
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/47—Condensation polymers of aldehydes or ketones
    • D21H17/49—Condensation polymers of aldehydes or ketones with compounds containing hydrogen bound to nitrogen
    • D21H17/51—Triazines, e.g. melamine
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/38—Coatings with pigments characterised by the pigments
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/50—Proteins
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/58—Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/66—Coatings characterised by a special visual effect, e.g. patterned, textured
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4023—Coloured on the layer surface, e.g. ink
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/406—Bright, glossy, shiny surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2479/00—Furniture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B32B2607/02—Wall papers, wall coverings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Definitions

  • the present invention relates to a glittering decorative paper and a thermosetting resin decorative board which can be used for various building materials such as building interior materials such as walls and floors, desks, dining tables, furniture and the like.
  • thermosetting resin decorative board represented by a melamine resin decorative board is obtained by impregnating a thermosetting resin such as melamine resin into a paper on which a pattern is printed on a paper base. This is generally manufactured by applying heat and pressure to cure the resin together with the backing substrate and the adherend such as overlay paper, and laminating and integrating them.
  • One of the decorative expressions of the decorative board or decorative paper is a metallic design, that is, a glittering design.
  • the decorative paper or thermosetting resin decorative board having such a glitter is obtained by adding a glitter pigment composed of a scale-like foil piece of a glitter material such as aluminum powder and mica to the pattern printing of the decorative paper. It is known to use a brilliant ink (see Patent Literature 1, Patent Literature 2, Patent Literature 3, Patent Literature 4, etc.).
  • glittering decorative paper which is a glittering ink containing a glittering pigment in the form of a scaly foil piece and has a glittering ink layer formed on a paper substrate, is made of melamine resin on the decorative paper.
  • the surface of the glittering ink layer has unevenness and unevenness, resulting in uneven design. May be impaired. Therefore, in order to improve surface unevenness, a decorative paper in which a transparent ink layer that covers and protects the glittering ink layer is formed on the glittering ink layer has been proposed (see Patent Document 3).
  • thermosetting resin decorative board As described above has a glitter, it is necessary to pay attention to surface unevenness.
  • the solution of providing a transparent ink layer on the surface and covering the glittering ink layer has a problem that an additional transparent ink layer is required.
  • a transparent ink layer When a transparent ink layer is added, the impregnating property of a resin solution such as melamine resin decreases, and air remains in the fiber of the paper substrate even after impregnation of the resin solution, which is a thermosetting resin.
  • the decorative board expands when heated, so that a so-called prister is likely to be generated (reduced heating prister resistance).
  • Patent Document 1 Japanese Patent Publication No. 52-55514
  • Patent Document 2 JP-A-53-56268
  • Patent Document 3 JP-A-54-96579
  • Patent document 4 JP-A-2000-86625
  • an object of the present invention is to provide a thermosetting resin decorative board or a decorative paper for the same as a decorative sheet having a glittering property.
  • the purpose of the present invention is to prevent the occurrence of unevenness without adding a transparent ink layer to the decorative paper surface and without reducing the heat-resistant blister resistance.
  • the glittering decorative paper of the present invention which solves the above-mentioned problems is provided with a glittering ink layer containing a glittering pigment consisting of a scaly foil piece of a glittering substance on a paper substrate.
  • the glossy decorative paper has a configuration in which a urethane resin emulsion is used in combination with aqueous resins such as casein resin and acrylic resin, as the ink resin of the glitter ink layer.
  • a glittering ink layer is provided as the outermost surface layer, and an aqueous resin such as casein resin or acrylic resin is used for the resin of the glittering ink layer.
  • an aqueous resin such as casein resin or acrylic resin is used for the resin of the glittering ink layer.
  • the fixation of the brilliant pigment is strengthened by the urethane resin emulsion-added casket, it is included in the impregnated resin solution when the aqueous impregnating resin solution such as melamine resin is impregnated.
  • the glittering ink layer does not dissolve or swell due to the water content, and the glittering pigment dispersed and held in the glittering ink layer is prevented from moving.
  • the occurrence of surface unevenness in glitter is improved.
  • a thermosetting resin decorative board is manufactured by subsequent hot-press molding, the movement of the glitter pigment due to the flow of the impregnated resin is suppressed, and the occurrence of glitter surface unevenness is improved.
  • the glittering thermosetting resin decorative plate of the present invention is configured to include a layer formed by impregnating and curing a thermosetting resin in the glittering decorative paper.
  • thermosetting resin decorative board With such a configuration, the effect of the decorative paper having glitter can be enjoyed on a thermosetting resin decorative board. That is, in a decorative paper having a glittering ink layer on the outermost surface layer, an aqueous resin such as casein resin or acrylic resin is used as the resin for the glittering ink layer. Even in the case of a decorative board made of glittering decorative paper, the bright pigment is firmly fixed by the urethane resin-emulsion-added kamitsu and the movement is suppressed. As a result, the occurrence of surface unevenness of glitter due to the impregnation of the decorative paper with the resin or the production of the thermosetting resin decorative board by hot pressing is improved.
  • an aqueous resin such as casein resin or acrylic resin
  • the occurrence of glittering surface unevenness when impregnated resin is impregnated is improved. Further, even when a thermosetting resin decorative board is manufactured by the subsequent hot-press molding, the occurrence of surface unevenness of the glitter is improved. In addition, it is not necessary to add a transparent ink layer that lowers the heat-plister resistance.
  • thermosetting resin decorative board having glitter of the present invention the occurrence of surface unevenness of glitter due to impregnation of the decorative paper with resin and formation of heat and pressure is improved.
  • FIG. 1 shows one example of the glittering decorative paper of the present invention (FIG. 1 (A)) and the glittering thermosetting resin-made decorative board of the present invention (FIG. 1 (B)). It is sectional drawing which illustrates a form.
  • FIG. 2 is a cross-sectional view conceptually illustrating the mechanism of the occurrence of surface unevenness.
  • the glittering decorative paper 10 illustrated in FIG. 1 (A) is obtained by forming a picture ink layer 2 (using a normal ink not containing a glittering pigment) on a paper substrate 1 and a scale of a glittering substance.
  • This is a decorative paper having a configuration in which the glittering ink layer 3 containing a glittering pigment, which is also a piece of foil, is formed by printing or the like in this order.
  • the brilliant ink layer 3 is formed as the outermost surface layer without any other layer on the layer, and the brilliant ink layer is made of casein grease, acryl grease or the like.
  • the urethane resin emulsion is used in combination with the aqueous resin.
  • the pattern ink layer 2 below the glittering ink layer 3 can be omitted depending on the design, but is usually provided for a higher design.
  • the decorative paper 10 having such a brilliant property is suitably used for a known thermosetting resin decorative panel represented by a melamine decorative panel, and is used for impregnation or hot-press molding at the time of production of the decorative panel. Occasionally the occurrence of surface unevenness of the glittering property is improved. Then, for example, a thermosetting resin decorative panel 20 having a brilliancy as shown in FIG. 1 (B) is obtained. [0015] That is, a thermosetting resin decorative board 20 having a brilliant property, which exemplifies one mode as a cross-sectional view of FIG.
  • the decorative paper 10 having the above-mentioned glitter is impregnated and cured with a thermosetting resin, and the decorative paper 10A having the glitter is sandwiched between the front and back, and the backing substrate 4 is provided on the back side of the decorative paper 10 and the overlay paper 5 is provided on the front side.
  • the glittering decorative paper according to the present invention is characterized by the resin composition of the glittering ink layer on the paper substrate and the layered positional relationship.
  • the configuration of conventionally known various types of paper for cosmetics used for decorative resin boards may be appropriately adopted depending on the application.
  • a titanium paper containing titanium white is typically used as the paper base material 1.
  • Other papers are also used.
  • paper such as kraft paper, high-quality paper, and Japanese paper.
  • the fiber of the paper substrate is usually a cellulose fiber.
  • mixed paper using resin fiber, glass fiber, or the like may be used.
  • a resin-impregnated paper obtained by impregnating these papers with a resin may be used.
  • the basis weight of the paper substrate is about 50 to 120 gZm 2 .
  • the pattern ink layer 2 may be formed by a known forming method such as gravure printing, offset printing, flexographic printing, or ink jet printing using a known ink.
  • the pattern ink layer 2 in the present invention is a layer which does not substantially contain a brilliant pigment as a flake-like foil of a brilliant substance as a brilliant pigment like the brilliant ink layer 3, and which is formed by a normal ink. It is a layer that expresses a pattern. If a water-based ink is used for the pattern ink layer 2 in consideration of the environment and the like, the casein resin, casein resin, and the like are used in the same manner as the glittering ink layer. An aqueous resin such as an acrylic resin may be used, and in that case, a urethane resin emulsion may be further used.
  • the brilliant ink layer 3 can be formed by a known forming method such as Daravia printing, similarly to the picture ink layer, except that the ink unique to the present invention is used.
  • the glitter ink layer and The pattern of the pattern ink layer is arbitrary, including the entire surface, and may be determined according to the intended use.
  • an ink is used in which a urethane resin emulsion is used in combination with an aqueous resin such as casein resin or acrylic resin as the binder resin.
  • Casein resin and acrylic resin are also typical resins for decorative paper ink for melamine resin, but these resins and urethane resin emulsions include water-based inks and water-based paints.
  • Casein fats are water-soluble and include milk proteins, plants, or modified products thereof.Acrylic fats are used in the form of emulsions, and are esters of acrylic acid and methacrylic acid.
  • the resin emulsion includes, for example, an emulsion of a carboxyl group-containing polyurethane resin.
  • the pigment used in the present invention as the glitter pigment of the glitter ink layer is a pigment in the form of a scaly foil made of a glitter substance.
  • a typical example of such a brilliant pigment is an aluminum-flake flake.
  • examples of the glittering pigment include scaly foil pieces of a metal material such as copper powder and brass powder.
  • a scaly foil piece of such a metal material has a metallic luster as a glitter.
  • the "glitter" can be obtained from a so-called pearl luster (pearl luster) or a pearl luster, which is also a luster pigment having a scaly foil with a luster.
  • a brilliant pigment, such as a scaly foil piece obtained by cutting a film (brilliant substance) that causes color interference, may be used.
  • the size of these brilliant pigments may be appropriately adjusted depending on the design, but usually, the particle size (circumscribed sphere radius or diagonal length) ranges from about 100 to about 100 / zm, especially about 5 to 30 m. It is.
  • the amount of the glitter pigment may be appropriately adjusted depending on the design, but is usually about 50 to 200% by mass relative to the resin content.
  • water-soluble organic solvents such as alcohols such as isopropyl alcohol and cellosolves such as ethylene glycol monomethyl ether are used. Can be used together.
  • FIG. 2A is a cross-sectional view conceptually showing the behavior of the resin solution 7 when impregnating a thermosetting resin such as melamine resin.
  • the resin solution 7 penetrates into the gaps between the glittering pigments g on the paper substrate 1 and the inside of the paper substrate 1.
  • the brilliant pigment g in the form of a scaly foil piece is oriented parallel or substantially parallel (horizontally in the drawing) to the surface of the paper substrate 1 during the ink transfer and drying process when forming the brilliant ink layer. (This orientation provides efficient light reflection for incident light and provides excellent glitter).
  • the glitter pigment g is originally dispersed and held in the glitter ink layer, but in FIG. 2, which is conceptual, the glitter ink layer is omitted for the sake of emphasis, and the glitter pigment layer is omitted. Only pigment g is drawn on the paper substrate.
  • Fig. 2 (B) conceptually shows a state in which the resin solution 7 is impregnated, then enters a drying hood and is dried. This time, volatile components such as water in the resin solution 7 evaporate from the inside of the paper base material 1 to the outside from between the glitter pigments g. At this time, the fixation of the bright pigment g is weakened by an aqueous volatile component such as moisture or heat during drying because the fixing of the glitter pigment g is performed by the aqueous binder resin, and the lower force of the glitter pigment g moves upward. Powered by the moving force of the component, it becomes a floating state and the orientation changes. Then, it is considered that the light reflection is reduced and glittering surface unevenness occurs.
  • the fixation of the glitter pigment imparts resistance to aqueous volatile components such as water, As a result, it is considered that the change in orientation during drying is suppressed, and the occurrence of surface unevenness is improved.
  • the glittering decorative paper of the present invention may have a layer other than the above as appropriate without departing from the spirit of the present invention.
  • a primer layer and a sealer layer provided between a paper base and a glitter ink layer, or between a paper base and a picture ink layer.
  • the glittering thermosetting resin decorative board of the present invention is characterized in that the decorative paper having the above-mentioned glittering properties is used as the decorative paper, and the other configurations are so-called so-called decorative papers.
  • Various configurations in the thermosetting resin decorative board may be appropriately adopted depending on the application.
  • a backing substrate / overlay paper is generally used as the adherend.
  • thermosetting resin decorative board is made by impregnating the decorative paper with a resin solution such as melamine resin to form an impregnated decorative paper, and then laminating the impregnated decorative paper together with another adherend and applying heat pressure. It is manufactured by hot press molding in which the impregnated resin is cured by heating.
  • the thermosetting resin of the resin solution to be impregnated into decorative paper prior to hot pressing may be a known resin according to the intended use.
  • a known resin for example, there is typically melamine resin, and in addition, guanamine resin, phenol resin, unsaturated polyester resin, and diaryl phthalate (DAP) resin.
  • DAP diaryl phthalate
  • the resin solution to be impregnated in the decorative paper is particularly aqueous, such as melamine resin
  • fixing of the glitter pigment in the glitter ink layer of the decorative paper is particularly resistant to water. For this reason, it is possible to improve the surface unevenness of the glittering surface caused by the resin impregnation.
  • the hot pressing may be performed by appropriately employing a hot pressing process for various thermosetting resin decorative boards such as a melamine decorative board.
  • a hot pressing process for various thermosetting resin decorative boards such as a melamine decorative board.
  • a backing substrate a resin-impregnated (uncured) adherend such as overlay paper is used, it is usually cured simultaneously with the hot pressing.
  • the fixation of the glittering pigment in the decorative paper is improved, the change in the orientation of the glittering pigment can be suppressed even with respect to the flow of the impregnated resin during hot pressing. as a result, It is possible to improve the occurrence of glittering surface unevenness during hot pressing.
  • the adherend 6 is a backing substrate 4, an overlay paper 5, or the like (see FIG. 1B).
  • the backing substrate 4 is a substrate for laminating on the back side of the decorative paper, bonding and integrating, and imparting a desired shape, thickness, mechanical strength and the like to the thermosetting resin decorative board.
  • a core paper obtained by impregnating a paper with an uncured thermosetting resin (typically, phenol resin or other resin impregnated in decorative paper) is used.
  • a wood base, an inorganic base, a metal base, or the like is used as a backing base on the underside of the core paper, or on the underside of the decorative paper when no core paper is used.
  • Wood base materials include veneer, plywood, particle board, fiber board, laminated wood and the like
  • metal base materials include, for example, metal plates such as iron and aluminum.
  • thermosetting resin to be impregnated (when the backing substrate is impregnated with a resin) is appropriately selected from the same thermosetting resins as listed in the impregnated decorative paper described above. Just do it.
  • the overlay paper 5 a conventionally known general material used for a thermosetting resin decorative board can be used, and typically, a transparent paper is impregnated with melamine resin. Melamine paper or resin impregnated paper can be used. Examples of the impregnated resin for the overlay paper 5 include the impregnated resin for the decorative paper.
  • thermosetting resin decorative board having glitter of the present invention is a laminate obtained by laminating and integrating the adherend and the decorative paper as described above, and further comprising another known adhesive layer.
  • a laminate or the like laminated on a substrate for example, a wooden substrate, an inorganic substrate, a metal substrate, a resin substrate, or the like may be used.
  • thermosetting resin decorative board (or, eventually, the use of decorative paper) is not particularly limited.
  • desks, dining tables, furniture such as a top plate, side plates, doors and other fittings, and the like. They include building interior materials such as walls and floors, interior materials of various vehicles such as automobiles, trains, and ships, and electric appliance cabinets such as televisions.
  • decorative paper 10 having glitter and thermosetting resin Decorative board 20 was produced.
  • a decorative paper having a desired glittering property is formed by forming a white solid pattern ink layer 2 of a colorant titanium white by gravure printing on a paper and an abstract pattern glittering ink layer 3 thereon.
  • a white solid pattern ink layer 2 of a colorant titanium white was formed by forming a white solid pattern ink layer 2 of a colorant titanium white by gravure printing on a paper and an abstract pattern glittering ink layer 3 thereon.
  • casein resin and acrylic resin emulsion were used as the resin for the ink of the pattern ink layer 2.
  • a urethane resin emulsion was used in combination with casein resin and (aqueous) acrylic resin, as the resin of the glitter ink layer 3.
  • Ink A and Ink B each contained 115 parts by mass of a scaly foil of aluminum (average particle size: 11 m) as a brilliant pigment with respect to 100 parts by mass of resin and volatile component (water).
  • Table 1 The ink contents of the examples and comparative examples are summarized in Table 1 together with the results.
  • the decorative paper 10 was impregnated with a melamine-fat solution containing water and dried to produce an impregnated decorative paper. Oil impregnation ⁇ Brightness unevenness during drying did not occur.
  • the impregnated decorative paper is placed on four core papers 4 impregnated with phenol resin as a backing substrate 4 (adherend 6), and furthermore, melamine resin is further placed thereon.
  • the overlay paper 5 having a transparent paper strength impregnated with the resin was placed thereon and subjected to hot press molding to produce a thermosetting resin decorative board 20 having a desired glitter as shown in FIG. 1 (B). After hot pressing, no glittering surface unevenness occurred.
  • FIG. 1 is a cross-sectional view illustrating one embodiment of a glittering decorative paper (A) and a thermosetting resin decorative board (B) according to the present invention.
  • FIG. 2 is a cross-sectional view conceptually illustrating a mechanism of occurrence of surface unevenness.

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Abstract

　熱硬化性樹脂化粧板、乃至はそれ用の化粧紙の意匠に光輝性を付与する場合に、樹脂含浸や熱圧成形時に起きる光輝性（感）の面ムラを、追加的に化粧紙表面に透明インキ層を付加する事なく防ぐ。 　紙基材１上の、光輝性物質の鱗片状箔片からなる光輝性顔料を含有する光輝性インキ層３を最表面層として有し、しかも光輝性インキ層のインキの樹脂にカゼイン樹脂、アクリル樹脂等の水性樹脂と共にウレタン樹脂エマルションを併用したインキを用いた、光輝性を有する化粧紙１０とする。間に通常のインキによる絵柄インキ層２設ければ更に高意匠となる。そして、この化粧紙１０にメラミン樹脂等の熱硬化性樹脂を含浸し、裏打ち基材４やオーバーレイ紙５等の被着体６と積層し熱圧成形して、樹脂を硬化させれば、光輝性を有する熱硬化性樹脂化粧板２０となる。

Description

明 細 書
光輝性を有する化粧紙及び熱硬化性樹脂化粧板
技術分野
[0001] 本発明は、壁、床等の建築物内装材、机、食卓、家具等、各種建材用途に用い得 る、光輝性を有する化粧紙と熱硬化性榭脂ィ匕粧板に関する。
背景技術
[0002] メラミンィ匕粧板に代表される熱硬化性榭脂ィ匕粧板は、紙基材に絵柄を印刷したィ匕 粧紙に、メラミン榭脂等の熱硬化性榭脂を含浸し、これを、裏打基材ゃオーバーレイ 紙等の被着体と共に、熱圧を加えて榭脂硬化させると共に積層一体化して製造され るのが一般的である。そして、前記化粧板乃至は化粧紙の意匠表現の一つに、メタリ ック調すなわち光輝性意匠がある。この様な光輝性を有する化粧紙乃至は熱硬化性 榭脂化粧板は、化粧紙の絵柄印刷に、アルミニウム粉末、雲母等の光輝性物質の鱗 片状箔片からなる光輝性顔料を添加した光輝性インキを用いることが知られて 、る ( 特許文献 1、特許文献 2、特許文献 3、特許文献 4、等参照)。
[0003] また、形状が鱗片状箔片の光輝性顔料を含有する光輝性インキで、紙基材上に光 輝性インキ層を形成した光輝性の化粧紙は、該化粧紙にメラミン榭脂等を含浸加工 する際、或いはその後の熱圧成形で熱硬化性榭脂化粧板とする際に、光輝性インキ 層の光 が面的にバラツキ、不均一となる面ムラが発生し、意匠性を損ねることが ある。そこで、面ムラ改善の為に、光輝性インキ層を被覆し保護する透明インキ層を 該光輝性インキ層上に塗布形成した化粧紙も提案されて ヽる (特許文献 3参照)。
[0004] 以上の如ぐ熱硬化性榭脂化粧板の意匠を光輝性を有するものとする場合には、 面ムラに注意する必要があり、またその改善策として特許文献 3が提案する、最表面 に透明インキ層を設けて光輝性インキ層を被覆する解決策は、追加的に透明インキ 層が必要となるという問題があった。また、透明インキ層を追加すると、メラミン榭脂等 の榭脂液の含浸性が低下し、榭脂液含浸後も紙基材の纖維中に空気が残留し、こ れが熱硬化性榭脂化粧板を加熱した際に膨張して、所謂プリスターを発生し易くなる (耐加熱プリスター性の低下）と云う問題もあった。 特許文献 1：実公昭 52— 55514号公報
特許文献 2：特開昭 53— 56268号公報
特許文献 3：特開昭 54 - 96579号公報
特許文献 4:特開 2000-86625号公報
発明の開示
発明が解決しょうとする課題
[0005] すなわち、本発明の課題は、熱硬化性榭脂化粧板乃至はそれ用の化粧紙の意匠 として光輝性を有するものとする場合に、榭脂含浸や熱圧成形時の光輝性 (感)の面 ムラ発生を、追加的に化粧紙表面に透明インキ層を付加せずに、また、耐加熱ブリス ター性も低下させること無ぐ防ぐことである。
課題を解決するための手段
[0006] 上記課題を解決すベぐ本発明の光輝性を有する化粧紙は、紙基材上に、光輝性 物質の鱗片状箔片カゝらなる光輝性顔料を含有する光輝性インキ層を有する光輝性 の化粧紙において、光輝性インキ層のインキの榭脂に、カゼイン榭脂、アクリル榭脂 等の水性榭脂と共にウレタン榭脂エマルシヨンを併用した構成とした。
[0007] この様な構成とすることで、光輝性インキ層を最表面層として設け、し力も光輝性ィ ンキ層のインキの榭脂に、カゼイン榭脂、アクリル榭脂等の水性樹脂が使用されてい ても、ウレタン榭脂エマルシヨン添カ卩によって光輝性顔料の固定が強固となる為力、メ ラミン榭脂等の水性含浸榭脂液を含浸加工するときに、含浸榭脂液中に含まれる水 分によって光輝性インキ層が溶解乃至は膨潤せず、光輝性インキ層中に分散保持さ れている光輝性顔料が動くのが抑制される。その結果、光輝性の面ムラ発生が改善 する。また、その後の熱圧成形で熱硬化性榭脂化粧板を製造するときも、含浸榭脂 の流動による光輝性顔料の動きが抑制され、光輝性の面ムラ発生が改善する。
[0008] また、本発明の光輝性を有する熱硬化性榭脂化粧板は、上記の光輝性を有する化 粧紙に熱硬化性榭脂を含浸、硬化させて成る層を含む構成とした。
[0009] この様な構成とすることで、上記光輝性を有する化粧紙による効果を、熱硬化性榭 脂化粧板でも享受できる。すなわち、光輝性インキ層が最表面層にある化粧紙で該 光輝性インキ層のインキの榭脂に、カゼイン榭脂、アクリル榭脂等の水性榭脂を使用 した光輝性の化粧紙を用いたィ匕粧板でも、ウレタン榭脂エマルシヨン添カ卩によって光 輝性顔料の固定が強固となり動きが抑制される。その結果、化粧紙への榭脂含浸時 や熱圧成形で熱硬化性榭脂化粧板製造時に起因する光輝性の面ムラ発生が、改善 する。
発明の効果
[0010] (1)本発明の光輝性を有する化粧紙によれば、含浸榭脂を含浸するときの、光輝性 の面ムラ発生が改善する。また、その後の熱圧成形で熱硬化性榭脂化粧板の製造 時でも光輝性の面ムラ発生が改善する。しかも、耐加熱プリスター性を低下させる透 明インキ層の追加も不要である。
(2)また、本発明の光輝性を有する熱硬化性榭脂化粧板によれば、化粧紙への榭脂 含浸時及び熱圧形成時に起因する光輝性の面ムラ発生が改善する。
発明を実施するための最良の形態
[0011] 以下、図面を参照しながら本発明の実施の形態を説明する。
[0012] § 1.概要:
先ず、図 1は、本発明の光輝性を有する化粧紙〔図 1 (A)〕と本発明の光輝性を有 する熱硬化性榭脂ィ匕粧板〔図 1 (B)〕の各一形態を例示する断面図である。また、図 2は、面ムラ発生のメカニズムを概念的に説明する断面図である。
[0013] 図 1 (A)に例示の光輝性を有する化粧紙 10は、紙基材 1上に、（光輝性顔料は含 まない通常のインキによる)絵柄インキ層 2、光輝性物質の鱗片状箔片カもなる光輝 性顔料を含む光輝性インキ層 3が、この順に印刷等で形成された構成の化粧紙であ る。本発明では光輝性インキ層 3は該層上には他層は無く最表面層として形成され、 し力ゝも該光輝性インキ層のインキの榭脂には、カゼイン榭脂ゃアクリル榭脂等の水性 榭脂と共にウレタン榭脂エマルシヨンを併用してある。なお、光輝性インキ層 3下の絵 柄インキ層 2は意匠次第では省略できるが、通常はより高意匠とする為に設ける。
[0014] この様な光輝性を有する化粧紙 10は、メラミン化粧板に代表される公知の熱硬化 性榭脂化粧板に好適には使用され、化粧板製造時の榭脂含浸や熱圧成形時に於 ける光輝性の面ムラ発生が改善される。そして、例えば図 1 (B)の様な光輝性を有す る熱硬化性榭脂ィ匕粧板 20が得られる。 [0015] すなわち、図 1 (B)の断面図としてその一形態を例示する光輝性を有する熱硬化性 榭脂化粧板 20は、裏打ち基材 4とオーバーレイ紙 5からなる被着体 6に、表裏を挟ま れる様に、上記の如き光輝性を有する化粧紙 10に熱硬化性榭脂を含浸硬化した光 輝性を有する化粧紙 10Aが、その裏側に裏打ち基材 4が表側にオーバーレイ紙 5が 被着体 6として積層一体ィ匕した構成の化粧板である。
[0016] § 2.光糠件を有する化粧紙:
次に、本発明の光輝性を有する化粧紙について説明する。本発明の光輝性を有す る化粧紙は、紙基材上の光輝性インキ層の榭脂組成とその層的位置関係とに特徴を 有するものであり、その他の構成については、所謂熱硬化性榭脂化粧板に使用され る従来公知の各種ィヒ粧紙の構成を用途に応じて適宜採用すれば良い。
[0017] 〔紙基材〕
例えば、紙基材 1としては、代表的にはチタン白を含有させたチタン紙が用いられる 力 この他の紙も用いられる。例えば、クラフト紙、上質紙、和紙等の紙である。また、 紙基材の繊維は、通常はセルロース繊維である力 この他、榭脂繊維或いはガラス 繊維等も併用した混抄紙等でも良い。また、これらの紙に榭脂を含浸させた榭脂含 浸紙等でも良い。また、紙基材の坪量は、 50— 120gZm2程度である。
[0018] 〔絵柄インキ層〕
また、絵柄インキ層 2は、公知のインキを用いてグラビア印刷、オフセット印刷、フレ キソ印刷、インキジェット印刷等の公知の形成方法で形成したもので良い。なお、本 発明に於ける絵柄インキ層 2は、光輝性インキ層 3の様に光輝性物質の鱗片状箔片 力 なる光輝性顔料を顔料として実質的に含まない層であり、通常のインキにより絵 柄を表現した層である。また、この絵柄インキ層 2のインキに、該絵柄インキ層につい て環境等を考慮して水性インキを用 Vヽるのであれば、インキには光輝性インキ層と同 様に、カゼイン榭脂、アクリル榭脂等の水性榭脂を用いても良ぐその場合には更に ウレタン榭脂エマルシヨンを用いても良 、。
[0019] 〔光輝性インキ層〕
光輝性インキ層 3は、本発明固有のインキを用いる他は、絵柄インキ層同様にダラ ビア印刷等の公知の形成方法で形成することができる。なお、光輝性インキ層及び 前記絵柄インキ層の絵柄は、全面ベタも含めて任意であり用途に応じたものとすれ ば良い。そして、本発明では、この光輝性インキ層のインキには、そのバインダーの 榭脂として、カゼイン榭脂、アクリル榭脂等の水性榭脂と共に、ウレタン榭脂エマルシ ヨンを併用したインキを用いる。なお、カゼイン榭脂、アクリル榭脂は、メラミン榭脂用 の化粧紙のインキとして代表的な榭脂でもあるが、これら榭脂、及び、ウレタン榭脂ェ マルシヨンとしては、水性インキや水性塗料等として従来公知のものを適宜採用すれ ば良い。この様な水性インキを用いることで、光輝性インキ層を環境配慮型に出来る 等の利点が得られる。なお、カゼイン榭脂としては水溶性で乳蛋白系、植物系、或い はこれらの変性物等があり、アクリル榭脂はエマルシヨン形態で使用されアクリル酸や メタクリル酸のエステル系等があり、ウレタン榭脂エマルシヨンには例えばカルボキシ ル基含有ポリウレタン榭脂のエマルシヨン等が挙げられる。
[0020] なお、ウレタン榭脂エマルシヨンの併用量は、適宜調整すれば良 、。例えば、ウレタ ン榭脂エマルシヨンの併用量が多すぎると、含浸榭脂乾燥後にはじき〔乾燥後の光 輝性インキ層が (周囲よりも)より疎水性となる為に、含浸するメラミン榭脂等の水性榭 脂液の濡れが悪くなり、撥じかれる現象〕が起きる等の不具合もでる。この為、水性榭 脂にカゼイン榭脂とアクリル榭脂とを用いる場合、これらの水性榭脂に対して、〔水性 榭脂〕 Z〔ウレタン榭脂エマルシヨン (榭脂固形分)〕 =8. 5/1. 5-1. 5/8. 5の範 囲とすると良い。ウレタン榭脂エマルシヨンが少な過ぎると、光輝性の面ムラ改善効果 が十分に得られない。
[0021] 一方、光輝性インキ層の光輝性顔料として本発明で用いるのは、光輝性物質で形 状が鱗片状箔片をした顔料である。この様な光輝性顔料としては、代表的にはアルミ -ゥムの鱗片状箔片がある。この他、該光輝性顔料としては、例えば、銅粉、真鍮粉 等の金属材料の鱗片状箔片等が挙げられる。これら金属材料の鱗片状箔片は光輝 性として金属光沢感が得られる。また、本発明に於ける「光輝性」としては、所謂パー ル光沢感 (真珠光沢感)でも良ぐパール光沢感も、やはり光輝性物質の鱗片状箔片 力もる光輝性顔料によって得られる。この様な、パール光沢感を与える該光輝性顔 料としては、例えば、二酸化チタン被覆雲母、酸塩ィ匕ビスマス等の箔片カゝら成る光輝 性顔料、或いは、屈折率の異なる 2種以上の榭脂層を数； z m以下で多層積層して干 渉色を生じさせたフィルム (光輝性物質)を断裁した鱗片状箔片カゝらなる光輝性顔料 等が挙げられる。なお、これらの光輝性顔料の大きさは、意匠により適宜調整すれば 良いが、通常、粒径 (外接球半径或いは対角線長）の範囲カ^ー 100 /z m程度、なか でも 5— 30 m程度である。また、光輝性顔料の添加量も意匠により適宜調整すれ ば良いが、通常、榭脂分に対して 50— 200質量％程度である。
[0022] なお、光輝性インキ層を形成する為のインキの溶剤としては、通常、水の他に、イソ プロピルアルコール等のアルコール類、エチレングリコールモノメチルエーテル等の セロソルブ類等の水溶性有機溶剤を併用することができる。
[0023] 以上の様なインキを用いて光輝性インキ層を形成することで、光輝性の面ムラ発生 が改善するのは、次の様な理由が考えられる。その理由を、図 2の面ムラ発生のメカ 二ズムを概念的に説明する断面図で説明する。
[0024] 先ず、図 2 (A)は、メラミン榭脂等の熱硬化性榭脂を含浸するときのその榭脂液 7の 挙動を概念的に示す断面図である。榭脂液 7は、紙基材 1上の光輝性顔料 gの隙間 カゝら紙基材 1内部に浸透して行く。形状が鱗片状箔片の光輝性顔料 gは、光輝性ィ ンキ層を形成時のインキの転移及び乾燥過程にて、紙基材 1の面に平行乃至は略 平行（図面では水平）に配向した状態となる（この配向が入射光に対する効率的な光 反射をもたらし優れた光輝性を与える)。なお、光輝性顔料 gは本来は光輝性インキ 層中に分散保持されているが、概念的である図 2では、強調する意味もあり光輝性ィ ンキ層の図示は省略してあり、光輝性顔料 gのみを紙基材上に描 ヽてある。
[0025] そして、図 2 (B)は、榭脂液 7を含浸した後、乾燥フードに入って乾燥させるときの 状態を概念的に示す。今度は、榭脂液 7中の水分等の揮発成分が、紙基材 1中等か ら、光輝性顔料 gの間から外部に蒸発して行く。このとき、光輝性顔料 gの固定が、水 性のバインダー榭脂による為に、水分等の水性揮発成分や乾燥時の熱により緩くな り、光輝性顔料 gの下側力 上側に移動する揮発成分の移動力によって動力されて、 浮いた様な状態となり配向が変化してしまう。すると、光反射が低下し、光輝性の面ム ラが発生すると考えられる。
[0026] ところが、本発明の如ぐ光輝性顔料 gを固定する榭脂にウレタン榭脂エマルシヨン を併用すると、光輝性顔料の固定が水等の水性揮発成分に対して耐性が与えられ、 その結果、乾燥時の配向変化が抑えられ、面ムラ発生が改善するものと思われる。
[0027] 〔その他の層〕
なお、本発明の光輝性を有する化粧紙は、本発明の趣旨を逸脱しない範囲内で、 上記以外の層を適宜有しても良い。例えば、紙基材と光輝性インキ層、或いは紙基 材と絵柄インキ層間に設ける、プライマー層ゃシーラー層等である。
[0028] S 3. 糠件を有する編更ィ 鋼旨ィ 板:
次に、本発明の光輝性を有する熱硬化性榭脂化粧板について説明する。本発明 の光輝性を有する熱硬化性榭脂化粧板は、その化粧紙として、上記の如き光輝性を 有する化粧紙を用 、た構成に特徴を有するものであり、その他の構成については、 所謂熱硬化性榭脂化粧板に於ける各種構成を用途に応じて適宜採用すれば良い。 例えば、被着体としては、図 1 (B)の熱硬化性榭脂化粧板 20で例示した様に、裏打 ち基材ゃオーバーレイ紙等が一般的である。
[0029] 〔熱圧成形〕
熱硬化性榭脂化粧板は、上記化粧紙にメラミン榭脂等の榭脂液を含浸させて含浸 化粧紙とした後、この含浸化粧紙を他の被着体と共に積層して熱圧を加えて含浸榭 脂を硬化させる熱圧成形によって製造される。
[0030] なお、熱圧成形に先立ち化粧紙に含浸させる榭脂液の熱硬化性榭脂としては、用 途に応じた公知の榭脂とすれば良い。例えば、代表的にはメラミン榭脂があり、この 他、グアナミン榭脂、フエノール榭脂、不飽和ポリエステル榭脂、ジァリルフタレート（ DAP)榭脂が挙げられる。本発明では、化粧紙に含浸させる榭脂液が、メラミン榭脂 の様に特に水性である場合に、化粧紙の光輝性インキ層中の光輝性顔料の固定が 特に水に対して耐性を有する為か、榭脂含浸時に起因する光輝性の面ムラ発生を 改善できること〖こなる。
[0031] そして、熱圧成形は、メラミン化粧板等の各種熱硬化性榭脂化粧板に於ける熱圧 成形工程を適宜採用すれば良 ヽ。裏打ち基材ゃオーバーレイ紙等の榭脂含浸され (未硬化の）被着体を用いる場合は、この熱圧成形の時に通常同時に硬化される。
[0032] また、本発明では、化粧紙中の光輝性顔料の固定が向上しているので、熱圧成形 時の含浸榭脂の流動に対しても、光輝性顔料の配向変化を抑えられる。その結果、 熱圧成形時に於ける光輝性の面ムラ発生を改善できることになる。
[0033] 〔被着体:裏打ち基材とオーバーレイ紙〕
なお、被着体 6として、裏打ち基材 4やオーバーレイ紙 5等である〔図 1 (B)参照〕。 裏打ち基材 4は、化粧紙の裏側に積層し接着一体化して、所望の形状、厚み、力学 的強度等を熱硬化性榭脂化粧板に付与する為の基材である。該裏打ち基材として は、未硬化の熱硬化性榭脂（代表的にはフエノール榭脂、この他前記化粧紙への含 浸榭脂等)を紙に含浸したコア紙が代表的である。また、コア紙を使用する場合はコ ァ紙の下側に、或いはコア紙を使用しない場合は化粧紙の下側に、木質基材、無機 質基材、金属基材等を裏打ち基材として使用することもできる。木質基材としては、 単板、合板、パーティクルボード、繊維板、集成材等があり、金属基材としては、例え ば、鉄、アルミニウム等の金属板等がある。
[0034] また、（裏打ち基材に榭脂含浸する場合の)含浸しておく熱硬化性榭脂としては、 前述含浸化粧紙で列記の如き熱硬化性榭脂と同様のものの中から適宜選択すれば 良い。なお、オーバーレイ紙 5としては、熱硬化性榭脂化粧板に用いられてきた従来 公知の一般的なものを使用でき、代表的には、透明性を備えた紙にメラミン榭脂を含 浸したメラミン紙榭脂含浸紙を用いることができる。オーバーレイ紙 5の含浸榭脂とし ては、前記化粧紙への含浸榭脂等が挙げられる。
[0035] 〔その他の層〕
なお、本発明の光輝性を有する熱硬化性榭脂化粧板は、上記の様な被着体と化 粧紙とが積層一体化した積層体が、公知の接着剤層を介して更に他の基材 (例えば 、木質基材、無機質基材、金属基材、樹脂基材等）に積層した積層物等でもよい。
[0036] 〔用途〕
なお、熱硬化性榭脂化粧板の用途 (或いはひいては化粧紙の用途）は、特に限定 されるものではないが、例えば、机、食卓、家具等の天板や側面板、扉等の建具、壁 、床等の建築物内装材、自動車、電車、船舶等の各種乗物の内装材、或いは、テレ ビ等の電化製品キャビネット、等である。
実施例 1
[0037] 図 1 (A)及び (B)の断面図の如き、光輝性を有する化粧紙 10及び熱硬化性榭脂 化粧板 20を作製した。先ず、酸ィ匕チタンを 20質量％含有する坪量 80g/m2のチタ ン
紙に、グラビア印刷で、着色剤チタン白による白色ベタ柄の絵柄インキ層 2と、その上 に、抽象図形柄の光輝性インキ層 3とを形成して、所望の光輝性を有する化粧紙 10 を作製した。なお、絵柄インキ層 2のインキの榭脂はカゼイン榭脂とアクリル榭脂エマ ノレシヨンを用いた。
[0038] また、光輝性インキ層 3のインキの榭脂には、カゼイン榭脂、（水性)アクリル榭脂、と 共にウレタン榭脂エマルシヨンを併用した。この光輝性インキのインキは、ウレタン榭 脂エマルシヨンは用いずカゼイン榭脂とアクリル榭脂エマルシヨンとを用いたインキ A (カゼイン榭脂：アクリル榭脂 = 12 : 0. 8質量比）と、ウレタン榭脂エマルシヨンのみを 用いたインキ Bとを、 A: B = 7 : 3質量比に混合して調整したものを用いた。なお、イン キ A及びインキ Bは、光輝性顔料として、各々、アルミニウムの鱗片状箔片（平均粒径 11 m)を榭脂分 100質量部に対して 115質量部含有し、揮発分 (水とイソプロピル アルコールの 1 : 1質量比混合溶剤） 65質量％の組成物を用いた。なお、実施例と比 較例のインキ内容は表 1に結果と共に纏めて示す。
[0039] そして、上記化粧紙 10に、水を含むメラミン榭脂液を含浸し乾燥して、含浸化粧紙 を作製した。榭脂含浸 ·乾燥時の光輝性の面ムラは発生しなカゝつた。
[0040] 次に、上記含浸化粧紙を、裏打ち基材 4 (被着体 6)としてフエノール榭脂を含浸し た 4枚のコア紙 4上に載置し、更にその上に、メラミン榭脂を含浸した透明紙力もなる オーバーレイ紙 5を載置して、熱プレス成形して、図 1 (B)の如き、所望の光輝性を有 する熱硬化性榭脂化粧板 20を作製した。熱プレス後に、光輝性の面ムラは発生しな かった。
実施例 2
[0041] 実施例 1に於!、て、インキ Aと、ウレタン榭脂エマルシヨンを含むインキ Bとの混合割 合を、 A: B= 9 : 1質量比に変更した他は、実施例 1と同様にして、光輝性を有する化 粧紙及び熱硬化性榭脂化粧板を作製した。
実施例 3
[0042] 実施例 1に於!、て、インキ Aと、ウレタン榭脂エマルシヨンを含むインキ Bとの混合割 合を、 A: B=8 : 2質量比に変更した他は、実施例 1と同様にして、光輝性を有する化 粧紙及び熱硬化性榭脂化粧板を作製した。
実施例 4
[0043] 実施例 1に於!、て、インキ Aと、ウレタン榭脂エマルシヨンを含むインキ Bとの混合割 合を、 A: B= 5 : 5質量比に変更した他は、実施例 1と同様にして、光輝性を有する化 粧紙及び熱硬化性榭脂化粧板を作製した。
[0044] 〔比較例 1〕
実施例 1に於いて、インキ Aと、ウレタン榭脂エマルシヨンを含むインキ Bとの混合割 合を、 A : B= 10 : 0質量比 (インキ Aのみ）に変更した他は、実施例 1と同様にして、 光輝性を有する化粧紙及び熱硬化性榭脂化粧板を作製した。
[0045] 〔比較例 2〕
実施例 1に於いて、インキ Aと、ウレタン榭脂エマルシヨンを含むインキ Bとの混合割 合を、 A： B = 0： 10質量比 (インキ Bのみ）に変更した他は、実施例 1と同様にして、 光輝性を有する化粧紙及び熱硬化性榭脂化粧板を作製した。
[0046] [表 1] 表 1 性能評価
Figure imgf000012_0001
〇：はじき無く良好、 厶：はじき若干有り
表 1の如ぐ実施例では各々、光輝性の面ムラが含浸時と熱圧成形時共に発生し なかった。しかし、比較例では各々、光輝性の面ムラが含浸時と熱圧成形時共に発 生した。また、インキの榭脂がウレタン榭脂エマルシヨンだけの比較例 2では、榭脂の 含浸、乾燥後のはじきが多くなつてしまった。
図面の簡単な説明
[図 1]本発明による光輝性を有する化粧紙 (A)と熱硬化性榭脂化粧板 (B)の各一形 態を例示する断面図。
[図 2]面ムラ発生のメカニズムを概念的に説明する断面図。
符号の説明
1 紙基材
2 絵柄インキ層
3 光輝'性インキ層
4 裏打ち基材
5 オーバーレイ紙
6 被着体
7 榭脂液
10 光輝性を有する化粧紙
10A 光輝性を有する化粧紙 (榭脂含浸硬化済)
20 光輝性を有する熱硬化性榭脂化粧板
g 光輝性顔料

Claims

請求の範囲
[1] 紙基材上に、光輝性物質の鱗片状箔片カゝらなる光輝性顔料を含有する光輝性イン キ層を有する光輝性の化粧紙において、
光輝性インキ層を最表面層として有し、且つ光輝性インキ層のインキの榭脂に、力 ゼイン樹脂、アクリル榭脂等の水性榭脂と共にウレタン榭脂エマルシヨンを併用した、 光輝性を有する化粧紙。
[2] 請求項 1記載の光輝性を有する化粧紙に熱硬化性榭脂を含浸、硬化させて成る層 を含む、光輝性を有する熱硬化性榭脂化粧板。
PCT/JP2004/013248 2003-09-12 2004-09-10 光輝性を有する化粧紙及び熱硬化性樹脂化粧板 WO2005025861A1 (ja)

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JP2005088220A (ja) 2005-04-07
EP1666244B1 (en) 2015-07-29
US20070036984A1 (en) 2007-02-15
JP4249579B2 (ja) 2009-04-02
EP1666244A1 (en) 2006-06-07
CN100532090C (zh) 2009-08-26

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